Methods and systems for removing interstitial material from superabrasive materials of cutting elements using energy beams

Abstract

A method of forming a cutting element for an earth-boring tool may include directing at least one energy beam at a surface of a volume of polycrystalline superabrasive material including interstitial material disposed in regions between inter-bonded grains of polycrystalline superabrasive material. The method includes ablating the interstitial material with the at least one energy beam such that at least a portion of the interstitial material is removed from a first region of the volume of polycrystalline superabrasive material without any substantial degradation of the inter-bonded grains of superabrasive material or of bonds thereof in the first region.

Description

TECHNICAL FIELD[0001]Embodiments of the present disclosure relate generally to forming cutting elements and, more particularly, to removing interstitial material from spaces between inter-bonded grains of superabrasive material in a superabrasive table of a cutting element with electromagnetic radiation.BACKGROUND[0002]Earth-boring tools for forming wellbores in subterranean earth formations generally include a plurality of cutting elements secured to a body. For example, fixed-cutter earth-boring rotary drill bits (also referred to as “drag bits”) include a plurality of cutting elements that are fixedly attached to a bit body of the drill bit. Similarly, roller cone earth-boring rotary drill bits may include cones that are mounted on bearing pins extending from legs of a bit body such that each cone is capable of rotating about the bearing pin on which it is mounted. A plurality of cutting elements may be mounted to each cone of the drill bit. In other words, earth-boring tools typ...

AI Technical Summary

Benefits of technology

This patent describes methods for making cutting tools for drilling through earth. The methods involve using energy beams to remove material from a volume of polycrystalline material in the cutting tool without damaging the structure of the material. This allows for the creation of cutting tools that have superior strength and durability. The technical effect of this patent is to provide a more efficient and precise way of making cutting tools for drilling through earth.

Problems solved by technology

The presence of the catalyst material in the diamond table may contribute to thermal damage in the diamond table when the cutting element is heated during use, due to friction at the contact point between the cutting element and the formation.

This differential in thermal expansion rates may result in relatively large compressive and tensile stresses at the interface between the diamond table and the substrate, and may cause the diamond table to delaminate from the substrate.

For example, cobalt thermally expands significantly faster than diamond, which may cause cracks to form and propagate within the diamond table, eventually leading to deterioration of the diamond table and ineffectiveness of the cutting element.

For example, the diamond crystals may graphitize at the diamond crystal boundaries, which may substantially weaken the diamond table.

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